Barrier fortification enhancement and building structural units

ABSTRACT

A barrier fortification structure includes a sidewall having an interior surface and an exterior surface opposite the interior surface, the interior surface surrounding an interior volume, a filling material within the interior volume, thereby forming a barrier, and a foam disposed on at least a portion of the exterior surface of the sidewall.

CROSS-REFERENCED APPLICATION

This application claims priority to U.S. Provisional Application No.61/122,244, filed on Dec. 12, 2008. U.S. Provisional Application No.61/122,244, filed on Dec. 12, 2008, is incorporated herein by referencein its entirety.

BACKGROUND

1. Field of the Disclosure

The present disclosure relates generally to building unit structures andmethods therefore. More particularly, the present disclosure relates toa structure including a sidewall enclosing an interior volume filledwith a filling material and having a foam on a side of the sidewallopposite the interior volume.

2. Description of Related Art

Barrier fortification enhancement and building structural units thathave been referred to as gabions, include a box-shaped fencing or cagethat is filled with aggregate material such as sand or stones to form awall or block. Many of the building structures include a layer ofmaterial between the fencing and aggregate to prevent the aggregate fromleaking. These building structures may be erected quickly by erectingthe cage and filling it with aggregate on site. These buildingstructures are used as barriers by, for example, the military, tostabilize shorelines against erosion, form retaining walls, floodwalls,dams, barrier protection from bullets and ammunition, and analogousstructural uses.

Presently, these barrier fortification enhancement and buildingstructural units that are in use are deteriorating. The layer ofmaterial between the fencing and aggregate may develop holes or tearsover time leaking the aggregate material such as sand. Portions of thecage or fencing may also corrode or break over time causing instabilityof the building structure. Currently, the predominant solution to thedeterioration of the building structures is replacement, which resultsin substantial labor and cost.

Accordingly, there is a need for a building unit structure that resistsdeterioration. There is a further need for a method and apparatus thatreinforces the building structure or repairs and prevents furtherdeterioration of a building structure in use that has begun todeteriorate.

SUMMARY OF THE DISCLOSURE

A barrier fortification structure is provided that includes a sidewallhaving an interior surface and an exterior surface opposite the interiorsurface, the interior surface surrounding an interior volume, a fillingmaterial within the interior volume, thereby forming a barrier, and afoam disposed on at least a portion of the exterior surface of thesidewall.

A method for forming a barrier fortification structure is also providedthat includes erecting the structure comprising a sidewall surroundingan interior volume, the interior volume being filled with a fillingmaterial forming a barrier, insulating and/or strengthening the sidewallby applying a foam on at least a portion of a side of the sidewallopposite the interior volume.

The above-described and other advantages and features of the presentdisclosure will be appreciated and understood by those skilled in theart from the following detailed description, drawings, and appendedclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of an exemplary embodiment of astructure according to the present disclosure without foam;

FIG. 2 is a perspective view of an exemplary embodiment of a sidewallaccording to the present disclosure in a flattened or collapsedcondition;

FIG. 3 is a perspective view of an exemplary embodiment of the sidewallaccording to the present disclosure in a partially an erected condition;

FIG. 4 is a perspective view of an exemplary embodiment of the sidewallaccording to the present disclosure in an erected condition;

FIG. 5 is a perspective view of an exemplary embodiment of the structureaccording to the present disclosure with foam on a portion of thesidewall;

FIG. 6 is a perspective view of an exemplary embodiment of a sidewallaccording to the present disclosure in an erected condition with foam ona portion of the sidewall;

FIG. 7 is a perspective view of an exemplary embodiment of a sidewallaccording to the present disclosure in a partially an flattenedcondition;

FIG. 8 is a perspective view of an exemplary embodiment of the sidewallaccording to the present disclosure in the flattened condition;

FIG. 9 is a top view of an exemplary embodiment of the sidewallaccording to the present disclosure in the flattened condition; and

FIG. 10 is a perspective view of an exemplary embodiment of a structureaccording to the present disclosure with foam on a portion of thesidewall having a component connected to the sidewall.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to the drawings and in particular to FIG. 1, an exemplaryembodiment of a structure according to the present disclosure isgenerally referred to by reference numeral 10. Structure 10 has asidewall 20. Sidewall 20 forms a sidewall that surrounds an interiorvolume 23 in an erected condition. As shown in FIGS. 3 through 6,sidewall 20 may be connected to a bottom 38 as shown in FIG. 3 and/or alid 28 as shown in FIG. 5. Sidewall 20 may have one or more holes 21.One or more holes 21 may be formed by mesh panels, such as, for example,a wire mesh cage.

Sidewall 20 is filled with filling material 26 to form a building unit,such as, a barrier, wall, block, or other building unit. Fillingmaterial 26 may be a filling material 26, such as, for example, stones,sand, concrete, soil, ash, brick, broken concrete, granite, limestone,sandstone, shingle, slag, stone, or any combinations thereof. Sidewall20 may be filled with filling material 26 on site by any suitable methodsuch as hand shovels, augers, pumps, earth movers of various types, orany combination thereof. Filling material 26 may be sized so that itwill not pass through one or more holes 21.

Sidewall 20 may have a layer of material 24 connected on a side ofsidewall 20 within interior volume 23. Layer of material 24 may beflexible. Layer of material 24 covers one or more holes 21. Covering oneor more holes 21 by layer of material 24 prevents filling material 26having a size smaller than one or more holes 21 from leaking out of oneor more holes 21. Layer of material 24 may be between filling material26 and lid 28, filling material 26 and bottom 38, and/or fillingmaterial 26 and sidewall 20. Layer of material 24 may be, for example,burlap or bonded felts of synthetic fibers which are of considerabletensile strength, but are porous so as to allow liquid to passtherethrough.

As shown in FIGS. 2 through 4, sidewall 20 may be in a collapsed orflattened condition and folded to the erected condition. The flattenedcondition allows for easier transportation of sidewall 10 by reducingsize of structure 10 providing a flat shape. A weight of sidewall 20 isreduced without filling material 26 therein allowing easiertransportation of sidewall 20. Adjacent edges of panels of sidewall 20are clipped together with connectors, such as, for example, stainlesssteel clips, galvanized spring steel ring clips, helical binders, ahelical spring binder clip, or any combination thereof. Wire mesh panels30, 32, 34, and 36 may make up sidewall 20 and sidewall 20 may beconnected to bottom 38 in the flattened condition. Wire mesh panels 30,32, 34, and 36 and bottom 38 are suitably secured together so as to berelatively hingeable. Sidewall 20 and bottom 38 in the flattenedcondition may be covered by a sheet 40 of flexible material 24, which issecured to wire mesh panels 30, 32, 34, and 36 and bottom 38. To erectthe cage and the sheet material 40, initially panels 34 and 30 arefolded to the position shown in FIG. 3, following which the excessportions of the material 40 at the corners are tucked inwardly asindicated by arrows 42, and then the end panels 32 and 36 are turnedupwardly until the position shown in FIG. 4 is reached, the extraportions of the material 40 forming flat fillets 44. Sidewall 20 may befilled with the filling material 26. Panels 30 and 34 may have tie hooks51 and 52. Tie hooks 51 and 52 link with each other as shown in FIG. 3when the panels 30 and 34 are erected, in order to keep the panelsconnected whilst the material 40 is tucked at the corner and then thepanels 32 and 36 are folded to the upright position.

Referring now to FIGS. 6 through 9, sidewall 20 may have sides 90 and92, ends 94 and 96 that may be connected to cage partition panels 98 and100, each of these components being of a wire mesh construction. Sides90 and 92, ends 94 and 96, cage partition panels 98 and 100 may behinged together by clip hinge rings 102 which enable respective portionsto be relatively hinged so that the inter-connected portions can berelatively hinged to the flattened condition, as shown in FIGS. 8 and 9.Lid 28 can be hinged relative to side 90, as bottom 38 can be hingedrelative to side 92. The sides 90 and 92 can be displaced relative toeach other as indicated by arrows 112 and 114 in FIG. 7, so that thesides 90, 92, the end panels 94 and 96 and the partition panels 98 and100 move to a flattened condition as indicated by FIGS. 8 and 9. Whenthese panels and walls are so moved to the flattened condition lid 28and bottom 38 can be swung onto the outsides of sides 90 and 92 toprovide the-flattened assembly.

Sidewall 20 may be readily manufactured under factory conditions andtransported to site where it is filled with filling material 26. Innersurfaces of sides 90 and 92 and inner surfaces of ends 94 and 96 may belined with layer of material 24 in order to contain filling materialthat is smaller than one or more holes 21. Inner surfaces of lid 28and/or bottom 38 may also be lined layer of material 24.

As shown in FIG. 5, foam 50 is applied to sidewall 10. Foam 50 may beapplied to structure 10 after structure 10 is erected to the erectedcondition. Foam 50 may be applied to structures that are in use with orwithout foam 50 applied thereon that have deteriorated. For example, asshown in FIG. 1, structure 10 may be in use without foam 50 and candeteriorate, and foam 50 is applied to deteriorated areas of structure10 or all of sidewall 20 to reinforce structure 10. Alternatively, foam50 is applied to structure 10 upon erection of structure 10 to resistdeterioration and extend a period of time structure is in use withoutdeterioration. Deterioration includes tears in layer of material 24allowing filling material to leak, corrosion or breakage of a portion ofsidewall 20, and/or any other structural failures.

It has been found by the present disclosure that the application of foam50 to structure 10 prevents deterioration, or, in a structure 10 that isalready in the erected condition and in use without foam 50, repairs andresists further deterioration to structure 10. Applying foam 50 tosurfaces of layer of material 24 and/or sidewall 20 protects thesurfaces from wear caused by, such as, for example, corrosion, impactfrom projectiles, weather, and/or other environmental conditions. Layerof material 24 can tear forming an aperture allowing filling material 26to leak out of structure 10. Foam 50 may be applied to the tear to shoreor repair layer of material 24 to eliminate the leak and maintainfilling material 26 within structure 10. Foam can used to repair holesand damaged areas to structure 10 by injecting the foam into the area inneed of repair to seal and repair the damaged area. The foam can also beused to repair the surface area of the foamed structure 10. Applicationof foam 50 eliminates or reduces the need to replace structures 10 thatare deteriorated and extends the lifetime of use of structure 10. Foam50 may be applied to structure 10 on site and without the need todisassemble structure 10. Foam 50 may be used on other buildingstructures, deteriorating structures, or temporary structures to resistdeterioration or prevent further deterioration.

Foam 50 is a foamed synthetic composition, such as, for example, spraypolyurethane foams. It has been found by the present disclosure that afoamed polymer is more tolerant to physical abuse than other materialssuch as a non-foamed resin that are more rigid. Foams generally can bystruck, punched, hit, and gouged and will only dent. Structuralintegrity will usually be maintained by foam. In contrast, othermaterials, such as non-foamed resins, may be more prone to cracking whensubject to physical abuse. It has also been found by the presentdisclosure that foams are more energy absorbing than other material,such as, solid plastics, since energy is absorbed when the cells arecrushed. Layer of material 24 is better protected from projectiles anddebris from explosions by foam than other material such as a solidplastic resin. Foam 50 may insulate structure 10, strengthen structure10, and resist impact while absorbing energy from bullets and otherammunition that may impact structure 10. Foam 50 is less solid than anon-foamed resin.

The Rigid Closed Cell Foam

Closed cell spray polyurethane and polyisocyanurate foams, includingtheir formulation and application in housing insulation applications arewell known in the art. In general, polyurethane or polyisocyanuratefoams are prepared by combining an (1) isocyanate, (2) a polyol, (3) ablowing agent, and optionally (4)—other additives. Each of thesecomponents and their processing to make polyurethane andpolyisocyanurate foam formulations for building insulation applicationsis described below. Foam 50 may have a density of about 1.0 to about10.0 pounds per cubic foot, and preferably about 3.0 pounds per cubicfoot.

1—The Isocyanate Component

Any organic polyisocyanate can be employed in polyurethane orpolyisocyanurate foam synthesis inclusive of aliphatic and aromaticpolyisocyanates. Preferred as a class are the aromatic polyisocyanates.Preferred aromatic polyisocyanates for rigid polyurethane orpolyisocyanurate foam synthesis include the polymethylene polyphenylisocyanates, particularly the mixtures containing from about 30 to about85 percent by weight of methylenebis(phenyl isocyanate) with theremainder of the mixture comprising the polymethylene polyphenylpolyisocyanates of functionality higher than 2. These polyisocyanatescan be used alone or in any combination. Suitable commercially availableisocyanates include: Lupinate® M20S from BASF, PAPI 27 from Dow,Rubinate® M from Huntsman, and Mondur® MR from Bayer.

The amount of isocyanate in polyurethane or polyisocyanurate foamformulations is generally in the range of about 40 to about 60 weightpercent of the total foam formulation.

2—The Polyol Component

Typical polyols used in the manufacture of rigid polyurethane orisocyanurate foams include, but are not limited to, (i) aromaticamino-based polyether polyols such as those based on mixtures of 2,4-and 2,6-toluenediamine condensed with ethylene oxide and/or propyleneoxide, (ii) aromatic alkylamino-based polyether polyols such as thosebased on ethoxylated and/or propoxylated aminoethylated nonylphenolderivatives, (iii) sucrose or sorbitol-based polyols such as those basedon sucrose derivatives and/or mixtures of sucrose and glycerinederivatives condensed with ethylene oxide and/or propylene oxide, (iv)polyols derived from natural products including without limitation soyand flaxseed oil, (v) aromatic polyester polyols such as those based oncomplex mixtures of phthalate-type or terephthalate-type esters formedfrom polyols such as ethylene glycol, diethylene glycol, or propyleneglycol. These polyols may used alone or in any combination.

Suitable commercially available polyols include: Voranol® 470× from Dow,Jeffol® A630 from Huntsman, Terate® 4020 from Kosa, Voranol® 370 fromDow.

The amount of polyol in the polyurethane or polyisocyanurate foamformulations is generally in the range of about 20 to about 40 weightpercent of the total foam formulation.

3—The Blowing Agent Component

The blowing agent component can be any blowing agent known to be usefulin the manufacture of polyurethane or polyisocyanurate foam. Generallythese materials include: fluorocarbons (including chlorofluorocarbons(CFCs), hydrochlorofluorocarbons (HCFCs), hydrofluorocarbons (HFCs),hydrocarbons (HCs), water, CO₂, fluoroesters, fluoroethers,fluoroketones, fluoroolefins (HFOs), chlorofluoroolefins (HCFOs) organicacids, ethers, esters, alcohols, and trans-1,2-dichloroethylene.

Preferred physical blowing agents are those that have some or all of thefollowing are non-flammable, liquid, have a low molecular weight, no orlow (<about 0.01) ozone depletion potential (ODP) and have a low globalwarming potential (GWP) (that is a GWP of less than about 1500, morepreferably about 1000 or less, still more preferably less than about500, and most preferably less than about 150):

Suitable physical blowing agents include but are not limited to:

HCFCs and HFCs of from about 1-4 carbon atoms, and HCs of from about 4-6carbon atoms.

In certain embodiments, pentafluoropropenes are preferred, includingparticularly those pentafluoropropenes in which there is a hydrogensubstituent on the terminal unsaturated carbon, such asCF₃CF═CFH(HFO-1225yez), particularly since applicants have discoveredthat such compounds have a relatively low degree of toxicity incomparison to at least the compound CF₃CH═CF₂ (HFO-1225zc).

The term “HFO-1234” is used herein to refer to all tetrafluoropropenes.Among the tetrafluoropropenes are included 1,1,1,2-tetrafluoropropene(HFO-1234yf) and both cis- and trans-1,1,1,3-tetrafluoropropene(HFO-1234ze). The term HFO-1234ze is used herein generically to refer to1,1,1,3-tetrafluoropropene, independent of whether it is the cis- ortrans-form. The terms “cisHFO-1234ze” and “transHFO-1234ze” are usedherein to describe the cis- and trans-forms of1,1,1,3-tetrafluoropropene respectively. The term “HFO-1234ze” thereforeincludes within its scope cisHFO-1234ze, transHFO-1234ze, and allcombinations and mixtures of these.

The term “HFO-1233” is used herein to refer to all trifluoromonochloropropenes. Among the trifluoromonochloropropenes are included1,1,1,trifluoro-2,chloro-propene (HFO-1233xf) and both cis- andtrans-1,1,1-trifluo-3,chlororopropene (HFO-1233zd). The term HFO-1233zdis used herein generically to refer to 1,1,1-trifluo-3,chloro-propene,independent of whether it is the cis- or trans-form. The terms“cisHFO-1233zd” and “transHFO-1233zd” are used herein to describe thecis- and trans-forms of 1,1,1-trifluo,3-chlororopropene, respectively.The term “HFO-1233zd” therefore includes within its scope cisHFO-1233zd,transHFO-1233zd, and all combinations and mixtures of these.

The term “HFO-1225” is used herein to refer to all pentafluoropropenes.Among such molecules are included 1,1,1,2,3 pentafluoropropene(HFO-1225yez), both cis- and trans-forms thereof. The term HFO-1225yezis thus used herein generically to refer to 1,1,1,2,3pentafluoropropene, independent of whether it is the cis- or trans-form.The term “HFO-1225yez” therefore includes within its scopecisHFO-1225yez, transHFO-1225yez, and all combinations and mixtures ofthese.

HFOs derived from 365mfc including without limitation HFO-1354 andHFO-1345 may also be used as blowing agents in this application.

Preferred physical blowing agents include but are not limited to:1,1-dichloro-1-fluoroethane (HCFC-141b); 1,1,1,2-tetrafluoroethane(HFC-134a); 1,1,1,2-tetrafluoroethane (HFC-134);1-chloro-1,1-difluoroethane; 1,1,1,3,3-pentafluorobutane(HFC-142b);1,1,1,2,3,3,3-heptafluoropropane (HFC-227ea); difluoroethane;1,1,1,3,3-pentafluoropropane (HFC-245fa), 1,1,1,3,3-pentafluorobutane(HFC-365mfc), 1,1,1,2-tetrafluoroprop-1-ene (HFO-1234yr),1,2,3,3,3-pentafluoroprop-1-ene (HFO-1225ye),1-chloro-3,3,3-trifluoroprop-1-ene (HFO-1233zd, trans and/or cisisomers), 1,1,1,3-tetrafluoroprop-1-ene (HFO-1234ze, trans and/or cisisomers) and combinations of any of the foregoing or combinations of anyof the foregoing with other suitable blowing agents.

Suitable commercially available physical blowing agents include ENOVATE®245fa from Honeywell and SOLKANE® 365mfc available from Solvay. Whenused alone these materials are present in an amount of about 3 to about15 weight percent of the total foam formulation. When 245fa and 365mfcare used in combination they may be used in any combination howeverphysical blowing agent compositions which are 245fa rich (i.e., >50weight percent of the physical blowing agent composition is composed ofHFC-245fa).

Chemical blowing agents include but are not limited to compounds thatreact with the isocyanate to liberate a gas. Preferred chemical blowingagents include water and organic acids like formic acid.

Generally speaking, the amount of blowing agent present in the foamformulation is dictated by the desired foam densities of the finalpolyurethane or polyisocyanurate foams products. The polyurethane andpolyisocyanurate foams produced can vary in density from about 1.0 toabout 6.0 pounds per cubic foot, more preferably from about 1.5 to about4.0 pounds per cubic foot and most preferably 1.8 to 4 pound per cubicfoot. The density obtained is a function of how much of the blowingagent, or blowing agent mixture, is present in the A and/or Bcomponents, or that is added at the time the foam is prepared.

The amount of physical blowing in the polyurethane or polyisocyanuratefoam formulations is generally in the range of about 3 to about 15weight percent of the total foam formulation while the amount ofchemical blowing agent in such formulations is generally in the range ofabout 0 to about 3 weight percent of the total foam formulation.

4—Catalysts:

Any catalyst useful in the manufacture of polyurethane and/orpolyisocyanurate foam may be used in the invention. Catalysts used inthe manufacture of polyurethane foams are typically tertiary aminesincluding, but not limited to, N-alkylmorpholines, N-alkylalkanolamines,N,N-dialkylcyclohexylamines, and alkylamines where the alkyl groups aremethyl, ethyl, propyl, butyl and the like and isomeric forms thereof, aswell as heterocyclic amines. Typical, but not limiting, examples aretriethylenediamine, tetramethylethylenediamine,bis(2-dimethylaminoethyl)ether, triethylamine, tripropylamine,tributylamine, triamylamine, pyridine, quinoline, dimethylpiperazine,piperazine, N,N-dimethylcyclohexylamine, N-ethylmorpholine,2-methylpiperazine, N,N-dimethylethanolamine, tetramethylpropanediamine,methyltriethylenediamine, and mixtures thereof.

The amount of amine catalyst in the polyurethane foam formulation isgenerally in the range of about >0 to about 5 weight percent of thetotal foam formulation.

Optionally, non-amine polyurethane catalysts may be used in thepolyurethane foam formulation. Typical of such catalysts areorganometallic compounds of lead, tin, titanium, antimony, cobalt,aluminum, mercury, zinc, nickel, copper, manganese, zirconium, andmixtures thereof. Exemplary catalysts include, without limitation, lead2-ethylhexoate, lead benzoate, ferric chloride, antimony trichloride,and antimony glycolate. A preferred organo-tin class includes thestannous salts of carboxylic acids such as stannous octoate, stannous2-ethylhexoate, stannous laurate, and the like, as well as dialkyl tinsalts of carboxylic acids such as dibutyl tin diacetate, dibutyl tindilaurate, dioctyl tin diacetate, and the like.

The amount of non-amine catalyst in the polyurethane foam formulationsis generally in the range of about >0 to about less than 1 weightpercent of the total foam formulation.

In the preparation of polyisocyanurate foams, trimerization catalystsare used for the purpose of converting excess (i.e., greater than theamount required to react with the polyol and other isocyanate-reactivecomponents in the foam formulation). Any trimerization catalyst known tobe useful in the manufacture of polyisocyanurate foam may be employed inthe present invention. These catalysts include, but are not limited to,glycine salts and tertiary amine trimerization catalysts, alkali metalcarboxylic acid salts, and mixtures thereof. Preferred species withinthese classes are potassium acetate, potassium octoate, andN-(2-hydroxy-5-nonylphenol)methyl-N-methylglycinate.

The amount of trimerization catalyst in the polyisocyanurate foamformulation is generally in the range of about >0 to about less than 5weight percent of the total foam formulation.

5—Other Additives:

There are numerous additives that may be added to the foam formulationto optimize properties of the formulation. They include withoutlimitation: surfactants, cell stabilizers, flame retardants, viscositymodifiers, crosslinking agents, solubilizers, dispersing agents,colorants, adhesion promoters, vapor pressure suppressants andstabilizers. These are all well known in the art. Generally additivesare present in the foam formulation in an amount of >0 to about 15weight percent of the total foam formulation.

Closed-cell spray foam suitable for this application preferably have thefollowing nominal properties:

ASTM Property Test Unit Value Nominal Density: D-1622 lbs/ft³ 1.5-4.0Sprayed-in-Place R Value at 75° F. mean C-518 R/inch 5.0-8.0temperature, measured 6 months after foam manufacture CompressiveStrength: D-1621 Psi 20-60 Parallel to Rise Tensile Strength D-1623 Psi 30-100 Closed Cell Content D-2856 % >80

Useful closed-cell spray foams are disclosed in U.S. Pat. Nos.6,414,046; 7,214,294; 6,843,934, 6,806,247, 6,790,820; 6,784,150, amongothers which are incorporated herein by reference.

Useful closed-cell spray foams include Comfort Foam® FE178, FE158,CF178, CF158 commercially available from BASF Polyurethanes—FoamEnterprises (a division of BASF) of Florham Park, N.J.; BaySeal™ 2.0commercially available from BaySystems (a division of Bayer) of Spring,Tex.; Corbond® commercially available from Corbond of Bozeman, Mont.;HeatLok Soy 0240 commercially available from Demilec USA of Arlington,Tex.; Styrofoam™ 2.0 commercially available from Dow Chemical Company ofMidland, Mich.; PF-173, PF-193 commercially available from Gaco Westernof Seattle, Wash.; Permax commercially available from Resin TechnologyDivision (a division of Henry Co.) of Ontario, Calif.; Foam Lok™FL-2000™ commercially available from Lapolla Coatings of Houston, Tex.;InsulStar® commercially available from NCFI Polyurethanes (formerlyNorth Carolina Foam Industries) of Mt. Airy, N.C.; andDuraFoam—Duraseal™ 1.9 commercially available from Urethane ContractorSupply Company of Phoenix, Ariz.

6—Preparation and Application of the Rigid Closed Cell Foam

The preparation of polyurethane and polyisocyanurate foam is well knownin the art. It is convenient in many applications to provide thecomponents for polyurethane or polyisocyanurate foams in pre-blendedfoam formulations. Most typically, the foam formulation is pre-blendedinto two components. The isocyanate or polyisocyanate compositioncomprises the first component, commonly referred to as the “A”component. The polyol or polyol mixture, surfactant, catalyst(s),blowing agent(s), flame retardant, and other isocyanate reactivecomponents comprise the second component, commonly referred to as the“B” component. While the surfactant, catalyst(s) and blowing agent areusually placed in the “B” component, they also may be added to the “A”side, or added to both the “A” and “B” sides.

When spray foam is applied, the A-side chemicals (e.g. polyisocyanate)and B-side chemicals are mixed in appropriate amounts, typically equalamounts by volume, and then atomized into a mist. This mixing is done ina spray gun. The polyurethane or polyisocyanurate foam is created as thetwo chemicals mix and are deposited on structure 10. Optionally, fireretardant, colorants, auxiliary blowing agents, water, and even otherpolyols can be added as a third stream to the mix head of the spray gun.

Structure 10 having foam 50 thereon may be used for barriers, walls,blocks, shoring walls, barracades, coastal supports, stabilizeshorelines against erosion, form retaining walls, floodwalls, dams,barrier protection from bullets and ammunition, and analogous uses.Structure 10 effectively combats erosion and is particularly suitablefor stabilizing and strengthening embankments. Structure 10 having foam50 thereon has some flexibility to allow some movement and change inshape should local ground subsidence occur. Strength and integrity ofstructure 10 are retained. Structure 10 may be porous and it is nottherefore normally necessary to incorporate drainage systems.

Foam 50 may be coated with a UV resistant material. The UV resistantmaterial may be silicone, polyurea, acrylic, urethane, asphalt coatings,membrane roof waterproofing sheets, pavers, aggregate, poured in-placeconcrete protection surfacing, or any combination thereof.

Foam 50 may be coated with an insect and/or pest (rats, mice, roaches,ants, spiders, etc.), resistant material. Coating foam 50 with insectand/or pest resistant material on structure 10 repels, reduces oreliminates pests such as insects, rodents, and other unwanted pests, inand around structure 10.

Filling material 26 may expand and/or contract due to environmentalconditions such as temperature and humidity. It has been found by thepresent disclosure that foam 50 maintains a connection to sidewall 20during environmental conditions such as freeze and thaw of fillingmaterial 26 and is able to permit movement due to freeze and thaw offilling material in contrast to a non-foamable resin that will flake offdue to expansion and/or contraction due to freezing and thawing. Foam 50may insulate structure 10. Insulating structure 10 reduces freeze andthaw of filling material 26 that can lead to instability or erosion offilling material 26.

Structure 10 may collect liquid within filling material 26 and/orinterior volume 23. One or more holes 21 drain liquid out of interiorvolume 23. Foam 50 may reduce water entry into the structure 10. Foam 50may be formed to have openings or ports to drain liquid from interiorvolume 23. Foam 50 may be waterproof and/or permeable allowing liquid todrain from interior volume 23. The collection of liquid in interiorvolume 23 may cause filling material 26 to swell applying force tosidewall 10 and foam 50. Similar to freezing and thawing describedherein, foam 50 is able to permit movement due to freezing and thawingas well as collection of liquid within interior volume 23. Foam can beused to flash drainage opening and penetrations.

Foam 50 may be a blast mitigation material and/or an energy absorptionmaterial. Foam 50 that is a blast mitigation material and/or an energyabsorption material maintains the structural integrity of structure 10to resist structural failure due to impact from a projectile or blast.As discussed herein, it has been found by the present disclosure that afoamed polymer is more tolerant to physical abuse than other materialssuch as a non-foamed resin. Foams generally can by struck, punched, hit,and gouged and will only dent. Structural integrity will usually bemaintained. In contrast, other materials, such as non-foamed resins, maybe more prone to cracking when subject to physical abuse. It has alsobeen found by the present disclosure that foams are also more energyabsorbing than other material, such as, solid plastics since energy isabsorbed when the cells are crushed. Layer of material 24 is betterprotected from projectiles and debris from explosions than othermaterial such as a solid plastic resin.

Foam 50 may have a color. Color may be added to foam 50 by dyes. Forexample, foam 50 may have a color that camouflages structure with thesurrounding environment. Such camouflage patterns and colors includeshades of green similar to plant life, white to camouflage with snow,tan similar to desert sand, and analogous camouflage colors andpatterns.

As shown in FIG. 6, sidewall 20 may include a first sidewall 27connected to a second sidewall 29 having a connection area 25 therebetween. Foam 50 may be applied to connection area 25. Foam 50 onconnection area 25 may adhere first sidewall 27 to second sidewall 29.Foam 50 may be applied to connection area 25 so that a continuoussurface that is substantially smooth and/or in the same plane is formed.

Structure 10 may be stacked or placed side-by-side to form largerstructures. Structure 10 may be erected to the erected condition and anadditional structure may be erected to the erected condition adjacent tostructure 10 or stacked upon structure 10. Structure 10 and theadditional structure form a connection area similar to connection area25. Foam 50 is applied to the connection area between structure 10 andthe additional structure so that a continuous surface that is asubstantially smooth surface and/or within the same plane is formed.Foam 50 may adhere structure 10 to the additional structure stackedthereon or adjacent thereto. Foam 50 may be applied to layer of material24 of structure 10 and a layer of material of the additional structureeither on a side opposite filling material 26 of structure 10 andfilling material of the additional structure or within interior volume23 of structure 10 and an interior volume of the additional structure.

Referring to FIG. 10, sidewall 10 may have a component 60 adheredthereto by foam 50. Component 60 may be placed on sidewall 10 and foam50 is applied to sidewall 10 and component 60 to adhere component 60 tosidewall 10. Foam 50 may be an adhesive. Foam 50 may be applied to aninterior side within interior volume 23 to connect component 60 tosidewall 10. Foam 50 may be applied to a side of sidewall oppositeinterior volume 23 to connect component 60 to sidewall 10. Component 60may be a barrier deterrent such as, for example, razor wire, barbedwire, concertina wire, and the like or lighting and/or wiring.

It should also be noted that the terms “first”, “second”, “third”,“upper”, “lower”, “above”, “below”, and the like may be used herein tomodify various elements. These modifiers do not imply a spatial,sequential, or hierarchical order to the modified elements unlessspecifically stated.

While the present disclosure has been described with reference to one ormore exemplary embodiments, it will be understood by those skilled inthe art that various changes may be made and equivalents may besubstituted for elements thereof without departing from the scope of thepresent disclosure. In addition, many modifications may be made to adapta particular situation or material to the teachings of the disclosurewithout departing from the scope thereof. Therefore, it is intended thatthe present disclosure not be limited to the particular embodiment(s)disclosed as the best mode contemplated, but that the disclosure willinclude all embodiments falling within the scope of the appended claims.

1. A barrier fortification structure comprising: a sidewall having aninterior surface and an exterior surface opposite said interior surface,said interior surface surrounding an interior volume; a filling materialwithin said interior volume, thereby forming a barrier; and a foamdisposed on at least a portion of said exterior surface of saidsidewall.
 2. The structure of claim 1, wherein said sidewall istransformable between a flattened condition and an erected condition,wherein in said erected condition, said sidewall is filled with saidfilling material, and in said flattened condition, said sidewall isflattened or collapsed upon itself without said filling materialtherein.
 3. The structure of claim 1, further comprising a layer ofmaterial covering said interior surface of said sidewall between saidsidewall and said filling material.
 4. The structure of claim 1, whereinsaid sidewall has a plurality of holes or is formed of a mesh-likematerial.
 5. The structure of claim 1, wherein said foam comprises arigid closed cell foam that comprises (a) a blowing agent, and (b) atleast one compound selected from the group consisting of: apolyurethane, a polyisocyanurate polymer and combinations thereof. 6.The structure of claim 5, wherein said blowing agent is at least oneselected from the group consisting of: 1,1-dichloro-1-fluoroethane(HCFC-141b); 1,1,1,2-tetrafluoroethane (HFC-134a);1,1,1,2-tetrafluoroethane (HFC-134); 1-chloro-1,1-difluoroethane(HCFC-142b); 1,1,1,3,3-pentafluorobutane(HFC-365mfc);1,1,1,2,3,3,3-heptafluoropropane (HFC-227ea); difluoroethane(HCFC-142b); 1,1,1,3,3-pentafluoropropane (HFC-245fa),1,1,1,2-tetrafluoroprop-1-ene (HFO-1234yf),1,2,3,3,3-pentafluoroprop-1-ene (HFO-1225ye),1-chloro-3,3,3-trifluoroprop-1-ene (HFO-1233zd, trans and/or cisisomer), 1,1,1,3-tetrafluoroprop-1-ene (HFO-1234ze, trans and/or cisisomer), water, formic acid, carbon dioxide, esters, chlorocarbons,ethers, fluoroethers and combinations thereof.
 7. The structure of claim5, wherein said blowing agent is selected from the group consisting of:1,1,1,3,3-pentafluoropropane, 1,1,1,3,3-pentafluorobutane, and mixturesthereof.
 8. The structure of claim 7, wherein said blowing agent is1,1,1,3,3-pentafluoropropane.
 9. The structure of claim 8, wherein saidfoam comprises at least one compound selected from the group consistingof: co-blowing agent, surfactant, polymer modifier, toughening agent,colorant, dye, solubility enhancer, rheology modifier, plasticizingagent, flammability suppressant, antibacterial agent, viscosityreduction modifier, filler, vapor pressure modifier, nucleating agent,catalyst, and a combination thereof.
 10. The structure of claim 1,wherein said foam has a density from between about 1.5 to about 10.0pounds per cubic foot.
 11. The structure of claim 1, wherein said foamis coated with a UV resistant material.
 12. The structure of claim 1,wherein said foam is coated with an insect and/or pest resistantmaterial.
 13. The structure of claim 1, wherein said foam is aninsulation material that insulates said interior volume.
 14. Thestructure of claim 1, wherein said foam is a blast mitigation materialand/or an energy absorption material.
 15. The structure of claim 1,wherein said foam is a color that camouflages the structure with itssurrounding environment.
 16. The structure of claim 1, wherein said foamis waterproof.
 17. The structure of claim 1, wherein said foam maintainsa connection to said sidewall during freeze and thaw of said fillingmaterial.
 18. The structure of claim 1, wherein said foam connects acomponent selected from the group comprising electrical wiring, lightingto said sidewall, a barrier deterrent, and an additional structure, tosaid sidewall.
 19. The structure of claim 3, wherein said layer ofmaterial has a hole therethrough, and wherein said foam is furtherapplied over said hole.
 20. The structure of claim 1, wherein said foamis permeable and drains liquid out of said interior volume.